US20040118069A1 - Structural thermal framing and panel system for assembling finished or unfinished walls with multiple panel combinations for poured and nonpoured wall - Google Patents

Structural thermal framing and panel system for assembling finished or unfinished walls with multiple panel combinations for poured and nonpoured wall Download PDF

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US20040118069A1
US20040118069A1 US10/732,100 US73210003A US2004118069A1 US 20040118069 A1 US20040118069 A1 US 20040118069A1 US 73210003 A US73210003 A US 73210003A US 2004118069 A1 US2004118069 A1 US 2004118069A1
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wall
stud
panel
walls
framing
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US7409800B2 (en
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Paul Budge
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JENTEC INDUSTRIES Inc
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JENTEC INDUSTRIES Inc
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/005—Girders or columns that are rollable, collapsible or otherwise adjustable in length or height
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
    • E04B2/58—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of metal
    • E04B2/60—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of metal characterised by special cross-section of the elongated members
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8652—Walls made by casting, pouring, or tamping in situ made in permanent forms with ties located in the joints of the forms
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2002/867—Corner details

Definitions

  • This invention relates in general to a building system for residential and commercial buildings. Specifically, to permanent, thermal panel forms for poured and nonpoured walls in combination with high strength thermally efficient structural framing members or studs.
  • Prior art traditionally concrete walls are built by erecting wooden or metal forms into which concrete is poured. These forms are structurally rigid and, when properly secured, produce a straight wall. Once the concrete has hardened, the forms are removed and either discarded or moved to the next construction site. Concrete, however, does not provide the most efficient thermal barrier, nor does it provide a suitable surface for attaching interior sheet rock and wall boards or exterior siding and facades. Erection and removal of these large heavy forms is a labor intensive procedure and transportation costs for moving the forms from one construction site to another is expensive. Most prior art building structures use large amounts of concrete and have elaborate engineered steel frames. Whereas, my invention uses minimal amounts of concrete in combination with other building materials and the steel frame having the ability to be adjusted to accommodate different wall widths and is used for the permanent support for the structural thermal framing and panel system.
  • Another type is an insulated, poured concrete wall having internal and external insulation, drywall or other surface preparation connecting areas which are continuous of and extending the entire or selected lengths of the wall and apparatus for the provision of windows into the wall.
  • This is elaborate and more expensive than my invention.
  • my invention has fewer parts to assemble making it more cost effective.
  • Another type is a method for constructing a wall of a building includes the steps of providing a footing form to outline a horizontal dimension for the wall. Having a wall form ring material between opposing sides of the footing form and allowing the poured wall forming material to set to provide a wall base. Having a first wall and a second wall being opposite to the first wall forming an upright structure forming a wall.
  • This system is more elaborate and more expensive than my invention.
  • This prior art system lacks the ability to adjust to a multi-width whereas, my invention has the ability to adjust making different width walls by adjusting the steel frame.
  • Another type is a building form system and apparatus including Tshaped and U-shaped lengths of extruded plastic or steel coupled at their sides by rigid links.
  • the links are preferably coupled at ninety degree angles along the lengths of the T-shaped and U-shaped elongated members.
  • This system has more assembled parts than my invention making it more costly and it takes more assembly time.
  • Another type is a concrete form system having plurality of foam panels which are interlocked transversely, horizontally and vertically by a plurality of connectors. This system is very expensive in comparison to my invention.
  • Another type is a prefabricated wall forming structure for constructing reinforced concrete wall employs insulating foam plastic panels that are interlocked into two parallel concrete impervious walls by I-beam channels that are spaced apart by tie elements.
  • the tie elements can support horizontal or vertical reinforcing bars and prevent the foam wall from spreading apart under the hydraulic pressure of the poured concrete.
  • This system has more parts to assemble than my invention making more costly assembly and this system lacks the ability to be adjustable.
  • My invention has an adjustable frame giving it the ability to adjust to different widths.
  • Another type is a modular wall construction system includes a box-like block form of expanded foam plastic material such as polystyrene having opposite, parallel, spaced apart side walls and end walls extending between upper and lower surfaces and defining an internal cavity for receiving concrete slurry.
  • This system takes more concrete to form the internal wall making it more expensive and less versatile than my invention.
  • Another type is a concrete structure made from precast concrete structures. Having an outer wall and an inner wall forming an inter-region between the walls allowing reinforcing concrete to be added. This is an elaborate system which is more costly than my invention.
  • Another type is a wall form assembly having a pair of form wall assemblies which are kept in preselected spaced parallel relationship by means of cross members fitted within end slots and interlocked by means of pins with elongated braces mounted for movement from a low profile position for transport to a high profile operative position in which the width dimension is transverse to the plane of the form wall for maximum resistance to bowing from the hydrostatic pressure of wet concrete.
  • This is a system for forming a wall than a wall itself.
  • my invention is a wall system which becomes the wall itself and has a framing stud which has the ability to adjust for different widths of wall.
  • My invention has very small amounts of concrete needed in combination with different types of building materials.
  • Another type is a building component comprising first and second high density foam panels each having inner and outer surfaces, top and bottom, and first and second ends, the panels arranged in spaced parallel relationship with their inner surfaces facing each other, and at least two bridging members extending between and through and molded into the panel members, each bridging members comprising a pair of elongated end plates oriented in the top to bottom direction of the panels and abutting against the outer surfaces of the panels, and at least one web member extending between and rigidly connected to the end plates, each web member oriented in the top to bottom direction of the panels and having a height substantially less than the height of the panels.
  • This system requires a large amount of concrete to construct the interior part of wall whereas, my invention takes less concrete in forming the interior part of the wall and my invention has the ability to be adjusted to different widths since the reinforcement frame has an adjustment feature allowing it to be of different widths.
  • Another type is a multi-component modular system for use in fabricating wall structures of the type which may be fortified with concrete or other similar materials.
  • This system has no adjustable feature for different widths where, my invention does.
  • My invention has a support frame which can be adjusted to different widths, therefore, one framing stud can be adjusted to multi-width wall thickness, thereby, having a multi use.
  • Another type is a masonry structure reinforcing and confinement apparatus is disclosed for enhancing the structural integrity under stress of masonry structures formed of a plurality of stacked masonry units.
  • This system is for a masonry system only.
  • My invention is for a wall forming system, therefore, my invention is not a masonry system.
  • Another type is a construction block to be used with other similar blocks in order to construct panels of a building which is formed of a pair of substantially planar panels located in juxtaposition and spaced apart forming a space between the panel.
  • This system is a block system whereas, my invention is a panel system.
  • Another type is an insulating form work for casting a concrete wall, the form work having a pair of side walls, each of which is made up of a plurality of coplanar edge-abutting modular panels made of insulating foam material. Each panel has upper and lower edges with coplanar slits provided there along, and a pair of vertical end edges respectively provided with a tongue-and-groove to form vertical tongue-and-groove joints with other like adjoining panels.
  • This system has a first group of angle-irons having vertical branches fitting into the upward slits of the panels and horizontal branches pierced with holes extending toward the panel inner face.
  • the panels are also interconnected by a second group of angle-irons having vertical branches fitting into the downward slits of the panels and horizontal branches also pierced with holes extending toward the panel inner face and overlapping the horizontal branches of the angle-irons of the first group.
  • the holes register together and the tie-rods hold the side walls together.
  • the tie-rods have a central portion between the side walls and bent end portions extending through the panels. Elbows between the portions fit into the rabbets.
  • Another type is a modular synthetic plastic concrete form structure for forming a concrete wall or free form or an enclosure having a curved corner.
  • the side panels are positioned in spaced opposed relation.
  • Ties connect the panels in transversely spaced relation and with the panels and the ties being permanently attached with the concrete poured between the panels as a reinforcing and heat insulator.
  • This system has ties that are not able to be adjusted to various widths by using the same framing stud for all different wall thickness, which makes my invention more unique.
  • Another type is a prefabricated module comprising a three-dimensional armature formed by welded wires and flat elements from light and/or heat-insulating material, retained on either side of the armature to form at least one continuous panel.
  • This system is very complex because of all the welded wires going vertical and horizontal. Because of the complex wire system involved, it's very labor intense making it costly to assemble whereas, my invention is more simplistic making it less labor intense and less costly. Also, my invention, having the adjustable feature that the same framing stud can be used for different width walls, makes my invention novel.
  • Another type is it has vertical members set in a common base each having spaced pairs of flanges with vertical recess between the flanges of each pair receiving and retaining fastening means by which plasterboard sheets are secured, in spaced relation to the vertical members and defining a molding cavity between metal foil on the facing surfaces of the sheets a core of no-fines concrete being set in said cavity.
  • This system has no adjustable framing studs that can be adjusted to various widths for wall width whereas, my invention has a framing stud that has the ability to be adjusted so the same framing stud can be used for various width walls, which makes my invention unique.
  • Another type is a wall unit assembly having a steel skeleton frame which cannot be adjusted but is rigid whereas, my invention is adjustable so the same framing stud can be used for various width walls, which makes my invention unique because of the adjustable feature.
  • FIG. 1 Shows a perspective break-out view of the thermal steel framing stud and insulated panel assembly.
  • FIG. 2 Shows a perspective break-out view of the steel framing stud and insulated concrete panel assembly.
  • FIG. 3 Shows a perspective view of the framing stud.
  • FIG. 4 Shows a blow-up view of the framing stud first and second ends with adjustable means.
  • FIG. 5 Shows a top view of a straight insulated panel.
  • FIG. 6 Shows a perspective view of a straight insulated panel.
  • FIG. 7 Shows a top view of an outside 90 degree corner insulated panel.
  • FIG. 8 Shows a perspective view of an outside 90 degree corner insulated panel.
  • FIG. 9 Shows a top view of an inside 90 degree corner insulated panel.
  • FIG. 10 Shows a perspective view of an inside 90 degree corner insulated panel.
  • FIG. 11 Shows a top view of an inside 45 degree corner insulated panel.
  • FIG. 12 Shows a perspective view of an inside 45 degree corner insulated panel.
  • FIG. 13 Shows a top view of an outside 45 degree corner insulated panel.
  • FIG. 14 Shows a perspective view of an outside 45 degree corner insulated panel.
  • FIG. 15 Shows a perspective view of a straight insulated panel.
  • FIG. 16 Shows a perspective blow-up view top and shaped headers.
  • FIG. 17 Shows a perspective view of a slotted angle.
  • FIG. 18 Shows a perspective view of a shaped header.
  • FIG. 19 Shows a perspective view of a shaped header.
  • FIG. 20 Shows a top view of the thermal steel framing stud and insulated panel assembly.
  • FIG. 21 Shows a top view of the steel framing stud and insulated concrete panel assembly.
  • FIG. 22 Shows a top view of a straight insulated concrete panel.
  • FIG. 23 Shows a perspective view of a straight insulated concrete panel.
  • FIG. 24 Shows a top view of a 45 degree corner insulated concrete panel.
  • FIG. 25 Shows a perspective view of a 45 degree corner insulated concrete panel.
  • FIG. 26 Shows a top view of a 90 degree corner insulation concrete panel.
  • FIG. 27 Shows a perspective view of a 90 degree corner insulated concrete panel.
  • FIG. 1, FIG. 2, FIG. 3, FIG. 4, FIG. 5, FIG. 6, FIG. 7, FIG. 8, FIG. 9, FIG. 10, FIG. 11, FIG. 12, FIG. 13, FIG. 14, FIG. 15, FIG. 16, FIG. 17, FIG. 18, FIG. 19, FIG. 20, FIG. 21, FIG. 22, FIG. 23, FIG. 24, FIG. 25, FIG. 26, and FIG. 27 comprises at least one framing stud assembly 30 , FIG. 3 and FIG. 4, having one first end 31 , FIG. 3 and FIG. 4, having sufficient thickness, width and length, having one web 33 , FIG. 3 and FIG. 4, having sufficient thickness, width and length, one flange 35 , FIG.
  • FIG. 4 having sufficient thickness, width and length, at least one interlock tab 38 , FIG. 4, having sufficient thickness, width and length, one top tab 39 , FIG. 3, having sufficient thickness, width and length, one bottom tab 41 , FIG. 3, having sufficient thickness, width and length, at least one electric utility hole 44 , FIG. 4, having sufficient area to accommodate electric conduit.
  • FIG. 1 shows a structural thermal framing and panel system with multiple panel combinations for nonpoured wall comprising of at least one said framing stud assembly 30 , FIG. 3, at least one straight insulated panel 46 , FIG. 5 and FIG. 6, having sufficient thickness, width and length, at least one outside 90 degree corner insulated panel 51 , FIG. 7 and FIG.
  • FIG. 8 having sufficient thickness, width and length and/or at least one inside 90 degree corner insulated panel 52 , FIG. 9 and FIG. 10, having sufficient thickness, width and length and/or having at least one inside 45 degree corner insulated panel 53 , FIG. 11 and FIG. 12, having sufficient thickness, width and length, and/or having at least one outside 45 degree corner insulated panel 54 , FIG. 13 and FIG. 14, having sufficient thickness, width and length all said panels having one top groove 47 , FIG. 5, FIG. 6, FIG. 7, FIG. 8, FIG. 9, FIG. 10, FIG. 11, FIG. 12, FIG. 13 and FIG. 14, having sufficient area to accommodate shaped header 55 , FIG. 18, having sufficient thickness, width and length and shaped header 56 , FIG.
  • FIG. 19 having sufficient thickness, width and length, at least one L shaped slotted connector angle 57 , FIG. 17, having sufficient thickness, width and length and having multiple slotted received hole 58 , FIG. 17, to accommodate top tab 39 , FIG. 3, and top tab 40 , FIG. 3, said panels having groove 48 having sufficient area to accommodate electric utility conduit, having slot 49 having sufficient area to accommodate said framing stud flange, having two inset area 50 having sufficient area to accommodate same framing stud flange. Said groove 48 , slot 49 , inset 50 are shown in FIG. 5, FIG. 6, FIG. 7, FIG. 8, FIG. 9, FIG. 10, FIG. 11, FIG. 12, FIG. 13 and FIG. 14.
  • FIG. 2 shows a structural thermal framing and panel system with multiple panel combinations for poured wall comprising of at least one said framing stud assembly 30 , FIG. 3, at least two straight thin insulated panel 59 , FIG. 22 and FIG. 23, having sufficient thickness, width and length, at least one 45 degree long corner thin insulated panel 60 , FIG. 24 and FIG. 25, having sufficient thickness, width and length and/or at least one 45 degree short corner thin insulated panel 61 , FIG. 24 and FIG. 25, having sufficient thickness, width and length, and/or at least one 90 degree long corner thin insulated panel 62 , FIG. 26 and FIG. 27, having sufficient thickness, width and length, and/or having at least one 90 degree short corner thin insulated panel 63 , FIG. 26 and
  • FIG. 27 having sufficient thickness, width and length.
  • the structural thermal framing and panel system for assembling finished or unfinished walls with multiple panel combinations for poured and nonpoured walls 29 make up components may be made from concrete, stone, brick, foam, plastic, wood, iron, steel, aluminum or any other type metal, polyurethane type composite with fiber glass, high density expanded polystyrene, plastic or any combination of these materials.
  • the structural thermal framing and panel system for assembling finished or unfinished walls with multiple panel combinations for poured and nonpoured walls of this invention has the ability to be installed in a fraction of the time compared to masonry or solid concrete walls with about the same or less in total material costs. Furthermore, the structural thermal framing and panel system has the additional advantages in that:
  • a permanent stud frame with a plurality of forms or building panels with a defined space for receiving filler, and wherein the framing stud substantially conforms to a portion of the forms or building panels and resists bending in the wall.

Abstract

A novel structural thermal framing and panel system for assembling finished or unfinished walls with multiple combinations for poured and nonpoured walls comprising of a permanent structural framing stud which can be adjusted to different wall thickness, a plurality of permanent forms, wherein the pluralities of permanent forms are interchangeable with various other permanent panel forms with or without defined spaces for receiving filler, and wherein the framing stud substantially conforms to a portion of the pluralities of panel forms and resists bending in the panel forms. The framing stud is the main structural element in the wall. A structural framing system in combination with insulated panel forms with various defined spaces for receiving filler, and wherein panels may not be prefinished to form a rigid substrate. A method of forming a combination of various poured or nonpoured filler walls to form a structural, solid filled wall, post and beam filled wall, or a solid insulated structurally framed nonfilled wall. A structural framing element with multiple usage for forming walls, a process for forming structural framed walls. A method of forming variable configuration key grooved panel forms to form a variety of different wall thickness and pour configurations to form post and beam, post and beam matrix, solid poured walls, and solid nonpoured walls. An economical multiple use building system with extremely high R values.

Description

    CROSS REFERENCE TO RELATED APPLICATIONS
  • This application is a continuation of application Ser. No. 10/658,649, filed Sep. 9, 2003, which was a continuation of Ser. No. 09/938,713, filed Aug. 23, 2001, both entitled “Structural Thermal Framing and Panel System for Assembling Finished or Unfinished Walls with Multiple Panel Combinations for Poured and Nonpoured Walls,” and to Provisional Application Serial No. 60/197,039, all of which are incorporated herein in their entirety, and to which priority is claimed.[0001]
    • BACKGROUND OF THE INVENTION
  • 1. Field of Invention [0002]
  • This invention relates in general to a building system for residential and commercial buildings. Specifically, to permanent, thermal panel forms for poured and nonpoured walls in combination with high strength thermally efficient structural framing members or studs. [0003]
  • 2. Description of Prior Art [0004]
  • Prior art, traditionally concrete walls are built by erecting wooden or metal forms into which concrete is poured. These forms are structurally rigid and, when properly secured, produce a straight wall. Once the concrete has hardened, the forms are removed and either discarded or moved to the next construction site. Concrete, however, does not provide the most efficient thermal barrier, nor does it provide a suitable surface for attaching interior sheet rock and wall boards or exterior siding and facades. Erection and removal of these large heavy forms is a labor intensive procedure and transportation costs for moving the forms from one construction site to another is expensive. Most prior art building structures use large amounts of concrete and have elaborate engineered steel frames. Whereas, my invention uses minimal amounts of concrete in combination with other building materials and the steel frame having the ability to be adjusted to accommodate different wall widths and is used for the permanent support for the structural thermal framing and panel system. [0005]
  • Another type is an insulated, poured concrete wall having internal and external insulation, drywall or other surface preparation connecting areas which are continuous of and extending the entire or selected lengths of the wall and apparatus for the provision of windows into the wall. This is elaborate and more expensive than my invention. Whereas, my invention has fewer parts to assemble making it more cost effective. [0006]
  • Another type is a method for constructing a wall of a building includes the steps of providing a footing form to outline a horizontal dimension for the wall. Having a wall form ring material between opposing sides of the footing form and allowing the poured wall forming material to set to provide a wall base. Having a first wall and a second wall being opposite to the first wall forming an upright structure forming a wall. This system is more elaborate and more expensive than my invention. This prior art system lacks the ability to adjust to a multi-width whereas, my invention has the ability to adjust making different width walls by adjusting the steel frame. [0007]
  • Another type is a building form system and apparatus including Tshaped and U-shaped lengths of extruded plastic or steel coupled at their sides by rigid links. The links are preferably coupled at ninety degree angles along the lengths of the T-shaped and U-shaped elongated members. This system has more assembled parts than my invention making it more costly and it takes more assembly time. [0008]
  • Another type is a concrete form system having plurality of foam panels which are interlocked transversely, horizontally and vertically by a plurality of connectors. This system is very expensive in comparison to my invention. [0009]
  • Another type is a prefabricated wall forming structure for constructing reinforced concrete wall employs insulating foam plastic panels that are interlocked into two parallel concrete impervious walls by I-beam channels that are spaced apart by tie elements. The tie elements can support horizontal or vertical reinforcing bars and prevent the foam wall from spreading apart under the hydraulic pressure of the poured concrete. This system has more parts to assemble than my invention making more costly assembly and this system lacks the ability to be adjustable. My invention has an adjustable frame giving it the ability to adjust to different widths. [0010]
  • Another type is a modular wall construction system includes a box-like block form of expanded foam plastic material such as polystyrene having opposite, parallel, spaced apart side walls and end walls extending between upper and lower surfaces and defining an internal cavity for receiving concrete slurry. This system takes more concrete to form the internal wall making it more expensive and less versatile than my invention. [0011]
  • Another type is a concrete structure made from precast concrete structures. Having an outer wall and an inner wall forming an inter-region between the walls allowing reinforcing concrete to be added. This is an elaborate system which is more costly than my invention. [0012]
  • Another type is a wall form assembly having a pair of form wall assemblies which are kept in preselected spaced parallel relationship by means of cross members fitted within end slots and interlocked by means of pins with elongated braces mounted for movement from a low profile position for transport to a high profile operative position in which the width dimension is transverse to the plane of the form wall for maximum resistance to bowing from the hydrostatic pressure of wet concrete. This is a system for forming a wall than a wall itself. Whereas, my invention is a wall system which becomes the wall itself and has a framing stud which has the ability to adjust for different widths of wall. My invention has very small amounts of concrete needed in combination with different types of building materials. [0013]
  • Another type is a building component comprising first and second high density foam panels each having inner and outer surfaces, top and bottom, and first and second ends, the panels arranged in spaced parallel relationship with their inner surfaces facing each other, and at least two bridging members extending between and through and molded into the panel members, each bridging members comprising a pair of elongated end plates oriented in the top to bottom direction of the panels and abutting against the outer surfaces of the panels, and at least one web member extending between and rigidly connected to the end plates, each web member oriented in the top to bottom direction of the panels and having a height substantially less than the height of the panels. This system requires a large amount of concrete to construct the interior part of wall whereas, my invention takes less concrete in forming the interior part of the wall and my invention has the ability to be adjusted to different widths since the reinforcement frame has an adjustment feature allowing it to be of different widths. [0014]
  • Another type is a multi-component modular system for use in fabricating wall structures of the type which may be fortified with concrete or other similar materials. This system has no adjustable feature for different widths where, my invention does. My invention has a support frame which can be adjusted to different widths, therefore, one framing stud can be adjusted to multi-width wall thickness, thereby, having a multi use. [0015]
  • Another type is a masonry structure reinforcing and confinement apparatus is disclosed for enhancing the structural integrity under stress of masonry structures formed of a plurality of stacked masonry units. This system is for a masonry system only. My invention is for a wall forming system, therefore, my invention is not a masonry system. [0016]
  • Another type is a construction block to be used with other similar blocks in order to construct panels of a building which is formed of a pair of substantially planar panels located in juxtaposition and spaced apart forming a space between the panel. This system is a block system whereas, my invention is a panel system. [0017]
  • Another type is an insulating form work for casting a concrete wall, the form work having a pair of side walls, each of which is made up of a plurality of coplanar edge-abutting modular panels made of insulating foam material. Each panel has upper and lower edges with coplanar slits provided there along, and a pair of vertical end edges respectively provided with a tongue-and-groove to form vertical tongue-and-groove joints with other like adjoining panels. This system has a first group of angle-irons having vertical branches fitting into the upward slits of the panels and horizontal branches pierced with holes extending toward the panel inner face. The panels are also interconnected by a second group of angle-irons having vertical branches fitting into the downward slits of the panels and horizontal branches also pierced with holes extending toward the panel inner face and overlapping the horizontal branches of the angle-irons of the first group. The holes register together and the tie-rods hold the side walls together. The tie-rods have a central portion between the side walls and bent end portions extending through the panels. Elbows between the portions fit into the rabbets. This system does not have the ability to be adjusted to various widths whereas, my invention has this ability making it more versatile, also, less labor intense. [0018]
  • Another type is a modular synthetic plastic concrete form structure for forming a concrete wall or free form or an enclosure having a curved corner. The side panels are positioned in spaced opposed relation. Ties connect the panels in transversely spaced relation and with the panels and the ties being permanently attached with the concrete poured between the panels as a reinforcing and heat insulator. This system has ties that are not able to be adjusted to various widths by using the same framing stud for all different wall thickness, which makes my invention more unique. [0019]
  • Another type is a prefabricated module comprising a three-dimensional armature formed by welded wires and flat elements from light and/or heat-insulating material, retained on either side of the armature to form at least one continuous panel. This system is very complex because of all the welded wires going vertical and horizontal. Because of the complex wire system involved, it's very labor intense making it costly to assemble whereas, my invention is more simplistic making it less labor intense and less costly. Also, my invention, having the adjustable feature that the same framing stud can be used for different width walls, makes my invention novel. [0020]
  • Another type is it has vertical members set in a common base each having spaced pairs of flanges with vertical recess between the flanges of each pair receiving and retaining fastening means by which plasterboard sheets are secured, in spaced relation to the vertical members and defining a molding cavity between metal foil on the facing surfaces of the sheets a core of no-fines concrete being set in said cavity. This system has no adjustable framing studs that can be adjusted to various widths for wall width whereas, my invention has a framing stud that has the ability to be adjusted so the same framing stud can be used for various width walls, which makes my invention unique. [0021]
  • Another type is a wall unit assembly having a steel skeleton frame which cannot be adjusted but is rigid whereas, my invention is adjustable so the same framing stud can be used for various width walls, which makes my invention unique because of the adjustable feature. [0022]
    • BRIEF SUMMARY OF THE INVENTION
  • Accordingly, besides the objects and advantages described above, several objects and advantages of the present invention are: [0023]
  • (a) to provide for an improved thermal-efficient, cost effective permanent wall framing and wall forming system. [0024]
  • (b) to provide for an improved wall forming system which holds the building panels in a desired position so the resultant wall is straight. [0025]
  • (c) to provide a permanent frame stud producing a finished wall which has much greater structural integrity than previous wall forming systems. [0026]
  • (d) to allow pluralities of forms or building panels define a space for receiving filler. [0027]
  • (e) to provide a framing stud that will resist bending in the wall. [0028]
  • (f) to provide a framing stud which is the substantial structural component in a filled or unfilled finished wall. [0029]
  • (g) to provide a permanent framing stud that allows the erection of a solid single panel form for pouring just a concrete header and poured corners, or panels that form a post and beam matrix concrete structure. [0030]
  • (h) to provide a panel with no defined spaces for receiving filler and is solely a steel framed wall. [0031]
  • (i) to provide for a specially designed and engineered framing stud which has a rigid center webbing and rigid outer flanges, this combination forms a structural stud with truss type strength. [0032]
  • (j) to provide when this structural stud is used in combination with concrete the structural properties of the stud is further improved. [0033]
  • (k) to allow the concrete to form around the structural webbing thereby becoming a part of the webbing. This webbing is connected to a rigid inner and outer cord or flange that is offset from the outer edge of the concrete, thus moving the compression and tension zone out from the center axis point. [0034]
  • (l) to allow the structural formed stud in combination with a thin concrete wall to be comparable in overall strength to a much thicker concrete wall. [0035]
  • (m) to provide for better seismic properties for the overall wall. [0036]
  • (n) to allow all panels or panel forms in this system to be prefinished on the exterior facings prior to delivery. [0037]
  • (o) to provide improved shear strength of the panel. [0038]
  • (p) to provide a keyed grooving process that allows the user the ability to easily modify the panel by sliding filler pieces in between two panel forms thereby allowing the panel the ability to form walls in various thickness and the ability to pour filler in defined areas within the panel to form posts and beams or to form openings in the poured wall for windows and doors. [0039]
  • (q) to provide multiple flange receptacle grooving or slots on both ends of the panel allowing for even more pour combinations and the ability to form various thickness of walls with one combination panel. [0040]
  • (r) to provide a framing stud with an adjustable feature allowing the frame support to adjust to various widths thereby one framing stud will fit various walls having different width thickness. [0041]
  • (s) to provide bend out stud brackets that are part of the framing for holding horizontal and/or vertical rebar in a desired configuration, thereby these brackets add structural strength to the webbing of the stud frame. [0042]
  • (t) to provide bend out brackets which are part of the framing stud for fastening to footings or other substrates without the use of “L”, “C”, or “U” channels. [0043]
  • It is an object of the present invention to provide an improved structural thermal framing panel system for assembling finished or unfinished walls with multiple panel combination for poured and nonpoured walls. [0044]
  • Other objects and features are readily apparent from the following description of certain preferred embodiments thereof taken in conjunction with the accompanying drawings although variations and modifications may be affected without departing from the sphere and the scope of the normal concepts of the disclosed invention. You will find further objects and advantages of the invention from a consideration of the ensuing descriptions and accompanying drawings. [0045]
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 Shows a perspective break-out view of the thermal steel framing stud and insulated panel assembly. [0046]
  • FIG. 2 Shows a perspective break-out view of the steel framing stud and insulated concrete panel assembly. [0047]
  • FIG. 3 Shows a perspective view of the framing stud. [0048]
  • FIG. 4 Shows a blow-up view of the framing stud first and second ends with adjustable means. [0049]
  • FIG. 5 Shows a top view of a straight insulated panel. [0050]
  • FIG. 6 Shows a perspective view of a straight insulated panel. [0051]
  • FIG. 7 Shows a top view of an outside 90 degree corner insulated panel. [0052]
  • FIG. 8 Shows a perspective view of an outside 90 degree corner insulated panel. [0053]
  • FIG. 9 Shows a top view of an inside 90 degree corner insulated panel. [0054]
  • FIG. 10 Shows a perspective view of an inside 90 degree corner insulated panel. [0055]
  • FIG. 11 Shows a top view of an inside 45 degree corner insulated panel. [0056]
  • FIG. 12 Shows a perspective view of an inside 45 degree corner insulated panel. [0057]
  • FIG. 13 Shows a top view of an outside 45 degree corner insulated panel. [0058]
  • FIG. 14 Shows a perspective view of an outside 45 degree corner insulated panel. [0059]
  • FIG. 15 Shows a perspective view of a straight insulated panel. [0060]
  • FIG. 16 Shows a perspective blow-up view top [0061]
    Figure US20040118069A1-20040624-P00001
    and
    Figure US20040118069A1-20040624-P00002
    shaped headers.
  • FIG. 17 Shows a perspective view of a slotted angle. [0062]
  • FIG. 18 Shows a perspective view of a [0063]
    Figure US20040118069A1-20040624-P00002
    shaped header.
  • FIG. 19 Shows a perspective view of a [0064]
    Figure US20040118069A1-20040624-P00001
    shaped header.
  • FIG. 20 Shows a top view of the thermal steel framing stud and insulated panel assembly. [0065]
  • FIG. 21 Shows a top view of the steel framing stud and insulated concrete panel assembly. [0066]
  • FIG. 22 Shows a top view of a straight insulated concrete panel. [0067]
  • FIG. 23 Shows a perspective view of a straight insulated concrete panel. [0068]
  • FIG. 24 Shows a top view of a 45 degree corner insulated concrete panel. [0069]
  • FIG. 25 Shows a perspective view of a 45 degree corner insulated concrete panel. [0070]
  • FIG. 26 Shows a top view of a 90 degree corner insulation concrete panel. [0071]
  • FIG. 27 Shows a perspective view of a 90 degree corner insulated concrete panel.[0072]
    • DRAWING REFERENCE NUMERALS
  • [0073] 29 The structural thermal framing and panel system for assembling finished or unfinished walls with multiple combinations for poured and nonpoured walls
  • [0074] 30 framing stud assembly
  • [0075] 31 first end
  • [0076] 32 second end
  • [0077] 33 web first end
  • [0078] 34 web second end
  • [0079] 35 flange first end
  • [0080] 36 flange second end
  • [0081] 37 slotted interlock receiver hole second end
  • [0082] 38 interlock tab first end
  • [0083] 39 top tab first end
  • [0084] 40 top tab second end
  • [0085] 41 bottom tab first end
  • [0086] 42 bottom tab second end
  • [0087] 43 rebar holder second end
  • [0088] 44 electric utility hole first end
  • [0089] 45 electric utility hole second end
  • [0090] 46 straight insulated panel
  • [0091] 47 top groove for header
  • [0092] 48 groove for electric utility conduit
  • [0093] 49 slot for framing stud flange
  • [0094] 50 inset area for framing stud flange
  • [0095] 51 outside 90 degree corner insulated panel
  • [0096] 52 inside 90 degree corner insulated panel
  • [0097] 53 inside 45 degree corner insulated panel
  • [0098] 54 outside 45 degree corner insulated panel
  • [0099] 55 top
    Figure US20040118069A1-20040624-P00002
    shaped header
  • [0100] 56 top
    Figure US20040118069A1-20040624-P00001
    shaped header
  • [0101] 57 L shaped slotted connector angle
  • [0102] 58 slotted receiver hole for top tab
  • [0103] 59 straight thin insulated panel
  • [0104] 60 45 degree long corner thin insulated panel
  • [0105] 61 45 degree short corner thin insulated panel
  • [0106] 62 90 degree long corner thin insulated panel
  • [0107] 63 90 degree short corner thin insulated panel
  • [0108] 64 concrete filler
  • [0109] 65 horizontal rebar
    • DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
  • The structural thermal framing and panel system for assembling finished or unfinished walls with multiple combination for pour and non poured wall [0110] 29, shown in FIG. 1, FIG. 2, FIG. 3, FIG. 4, FIG. 5, FIG. 6, FIG. 7, FIG. 8, FIG. 9, FIG. 10, FIG. 11, FIG. 12, FIG. 13, FIG. 14, FIG. 15, FIG. 16, FIG. 17, FIG. 18, FIG. 19, FIG. 20, FIG. 21, FIG. 22, FIG. 23, FIG. 24, FIG. 25, FIG. 26, and FIG. 27 comprises at least one framing stud assembly 30, FIG. 3 and FIG. 4, having one first end 31, FIG. 3 and FIG. 4, having sufficient thickness, width and length, having one web 33, FIG. 3 and FIG. 4, having sufficient thickness, width and length, one flange 35, FIG. 4, having sufficient thickness, width and length, at least one interlock tab 38, FIG. 4, having sufficient thickness, width and length, one top tab 39, FIG. 3, having sufficient thickness, width and length, one bottom tab 41, FIG. 3, having sufficient thickness, width and length, at least one electric utility hole 44, FIG. 4, having sufficient area to accommodate electric conduit. One second end 32, FIG. 3 and FIG. 4, having sufficient thickness, width and length, having one web 34, FIG. 3 and FIG. 4, having sufficient thickness, width and length, one flange 36, FIG. 4, having sufficient thickness, width and length, at least one slotted interlock receiver hole 37, FIG. 4, having sufficient area to accommodate interlock tab 38, FIG. 4, located on said first end 31, FIG. 3 and FIG. 4, one top tab 40, FIG. 3, having sufficient thickness, width and length, one bottom tab 42, FIG. 3, having sufficient thickness, width and length, at least one rebar holder 43, FIG. 4, having sufficient thickness, width and length and having sufficient area to accommodate required horizontal rebar, at least one electric utility hole 45, FIG. 4, having sufficient area to accommodate electric conduit, FIG. 1, shows a structural thermal framing and panel system with multiple panel combinations for nonpoured wall comprising of at least one said framing stud assembly 30, FIG. 3, at least one straight insulated panel 46, FIG. 5 and FIG. 6, having sufficient thickness, width and length, at least one outside 90 degree corner insulated panel 51, FIG. 7 and FIG. 8, having sufficient thickness, width and length and/or at least one inside 90 degree corner insulated panel 52, FIG. 9 and FIG. 10, having sufficient thickness, width and length and/or having at least one inside 45 degree corner insulated panel 53, FIG. 11 and FIG. 12, having sufficient thickness, width and length, and/or having at least one outside 45 degree corner insulated panel 54, FIG. 13 and FIG. 14, having sufficient thickness, width and length all said panels having one top groove 47, FIG. 5, FIG. 6, FIG. 7, FIG. 8, FIG. 9, FIG. 10, FIG. 11, FIG. 12, FIG. 13 and FIG. 14, having sufficient area to accommodate
    Figure US20040118069A1-20040624-P00002
    shaped header 55, FIG. 18, having sufficient thickness, width and length and
    Figure US20040118069A1-20040624-P00001
    shaped header 56, FIG. 19, having sufficient thickness, width and length, at least one L shaped slotted connector angle 57, FIG. 17, having sufficient thickness, width and length and having multiple slotted received hole 58, FIG. 17, to accommodate top tab 39, FIG. 3, and top tab 40, FIG. 3, said panels having groove 48 having sufficient area to accommodate electric utility conduit, having slot 49 having sufficient area to accommodate said framing stud flange, having two inset area 50 having sufficient area to accommodate same framing stud flange. Said groove 48, slot 49, inset 50 are shown in FIG. 5, FIG. 6, FIG. 7, FIG. 8, FIG. 9, FIG. 10, FIG. 11, FIG. 12, FIG. 13 and FIG. 14.
  • FIG. 2 shows a structural thermal framing and panel system with multiple panel combinations for poured wall comprising of at least one said framing [0111] stud assembly 30, FIG. 3, at least two straight thin insulated panel 59, FIG. 22 and FIG. 23, having sufficient thickness, width and length, at least one 45 degree long corner thin insulated panel 60, FIG. 24 and FIG. 25, having sufficient thickness, width and length and/or at least one 45 degree short corner thin insulated panel 61, FIG. 24 and FIG. 25, having sufficient thickness, width and length, and/or at least one 90 degree long corner thin insulated panel 62, FIG. 26 and FIG. 27, having sufficient thickness, width and length, and/or having at least one 90 degree short corner thin insulated panel 63, FIG. 26 and
  • FIG. 27, having sufficient thickness, width and length. Said [0112] panels 59, 60, 61, 62, 63 having concrete filler 64, FIG. 22, FIG. 23, FIG. 24, FIG. 25, FIG. 26 and FIG. 27, having sufficient thickness, width and length between said panels. The structural thermal framing and panel system for assembling finished or unfinished walls with multiple panel combinations for poured and nonpoured walls 29 make up components may be made from concrete, stone, brick, foam, plastic, wood, iron, steel, aluminum or any other type metal, polyurethane type composite with fiber glass, high density expanded polystyrene, plastic or any combination of these materials.
    • CONCLUSION AND SCOPE OF INVENTION
  • Accordingly, the reader will see that the structural thermal framing and panel system for assembling finished or unfinished walls with multiple panel combinations for poured and nonpoured walls of this invention has the ability to be installed in a fraction of the time compared to masonry or solid concrete walls with about the same or less in total material costs. Furthermore, the structural thermal framing and panel system has the additional advantages in that: [0113]
  • it provides an improved thermal-efficient, cost effective permanent wall framing and wall forming system which holds the building panels in a desired position so the resultant wall in straight. [0114]
  • it provides a finished wall which has much greater structural integrity than previous wall forming systems. [0115]
  • it provides for a permanent stud frame with a plurality of forms or building panels with a defined space for receiving filler, and wherein the framing stud substantially conforms to a portion of the forms or building panels and resists bending in the wall. [0116]
  • it allows the framing stud web to become part of a rigid inner and outer cord or flange that is offset from the outer edge of the concrete, thus moving the compression and tension zone out from the center axis point. [0117]
  • it provides comparable in overall strength to a much thicker concrete wall and also has better seismic properties. [0118]
  • it allows all panels or panel forms in this system to be prefinished on the exterior facings prior to delivery. [0119]
  • it allows the framing stud assembly to adjust to different wall thickness, so that the same framing stud assembly has multiple use. [0120]
  • it provides a wall forming system to utilize the structural strength of the framing stud assembly in reducing the amount of concrete and rebar needed to form a structurally sound wall. [0121]
  • it allows a plurality of permanent panel forms in combinations with or without concrete. [0122]
  • it provides bottom bend out tabs for holding the framing stud assembly to the footing or floor. [0123]
  • it provides top bend out tabs for holding the framing stud assembly to the adjoining form panels. [0124]
  • it allows panels to be precoated with cementitious fiber or wire type reinforced hard coat finish for exterior facing of the forms that can be taped or meshed at the seams and a finished coat. [0125]
  • it allows the ability to fasten the framing stud assembly to footings or other substrates without the use of “L”, “C”, or “U” channel usually required by prior art. [0126]
  • Although the description above contains many specifications, these should not be construed as limiting the scope of the invention but merely providing illustrations of some of the presently preferred embodiments of this invention. [0127]
  • Thus, the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given. [0128]

Claims (8)

What is claimed is:
1. A wall system, comprising:
a slotted connector angle suitable for securement to a floor at a location where a wall is desired to be built, said first slotted connector angle having slots spaced at a distance from one another corresponding to a desired spacing of studs;
a stud element comprising:
first and second flange elements; and
bottom and upper tab elements at the respective bottom and upper ends of said stud element, each bottom tab element being adapted for connection to a slot of the slotted connector angle; and
a wall panel, said wall panel adapted for securement to the flange elements of said stud element, so that a line of stud elements may be connected to adjacent slots in the slotted connector angle and to adjacent wall panels so as to form a portion of a wall.
2. A wall system according to claim 1, further comprising a slotted connector element for attachment to the upper tab elements of a line of stud elements in order to provide additional support to the portion of a wall formed by a plurality of stud elements secured to the slotted connector angle.
3. A wall system according to claim 1, further comprising:
means for connecting a second stud element to a first stud element that is affixed to the slotted connector angle, so that a line of second stud elements may be affixed to a line of first stud elements connected to the slotted connector angle so as to form a second portion of the wall;
4. A wall system according to claim 3, further comprising a slotted connector element for attachment to the upper tab elements of the second line of stud in order to provide additional support to the second portion of the wall formed by said second line of stud elements and associated wall panels.
5. A wall system according to claim 1, wherein the stud element further comprises a support element adapted to support horizontal steel reinforcement rods.
6. A wall system according to claim 3, wherein the stud element further comprises a support element adapted to support horizontal steel reinforcement rods in a location between the lines of wall panels attached to the first and second lines of stud elements.
7. A wall system according to claim 3, wherein there is a space between the wall panels attached to the first line of stud elements and the wall panels attached to the second line of stud elements, and further comprising cement poured into said space.
8. A wall system according to claim 1, wherein the slotted connector angle is L-shaped.
US10/732,100 2000-08-23 2003-12-10 Structural thermal framing and panel system for assembling finished or unfinished walls with multiple panel combinations for poured and nonpoured wall Expired - Lifetime US7409800B2 (en)

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